Apparatus and methods for producing a ceramic green body

ABSTRACT

An apparatus for producing a green body of ceramic-forming material can comprise a support device including at least one air bearing including a support surface with a plurality of apertures. In one example, the support surface is configured to circumscribe greater than 180° of a support area for the green body. In another example, the plurality of apertures include at least a quantity of apertures oriented with a fluid emitting axis extending at an oblique angle with respect to an extrusion axis. In still another example, the air bearing is adjustable. Methods for producing a green body also provide an air cushion between a support surface and the green body.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/227,944 filed on Sep. 8, 2011, the content of which is relied uponand incorporated herein by reference in its entirety, and the benefit ofpriority under 35 U.S.C. §120 is hereby claimed.

FIELD

The present disclosure relates generally to apparatus and methods forproducing a green body of ceramic-forming material and, moreparticularly, to apparatus and methods for producing such a green bodythat is supported by an air cushion.

BACKGROUND

Apparatus and methods are known to produce green bodies ofceramic-forming material that are subsequently fired into a honeycombceramic body for various applications. For example, a batch ofceramic-forming material is known to be extruded from an extrusion dieinto a green body. Conventional apparatus are known to support theextruded green body with an air bearing.

SUMMARY

The following presents a simplified summary of the disclosure in orderto provide a basic understanding of some example aspects described inthe detailed description.

In one example aspect, an apparatus for producing a green body ofceramic-forming material comprises an extruding device including a diemember. The extruding device is configured to extrude a batch ofceramic-forming material through the die member to form a green body.The apparatus further includes a support device including at least oneair bearing including a support surface with a plurality of apertures.The support surface is configured to circumscribe greater than 180° of asupport area for the green body. The apparatus further includes a fluidsource configured to be placed in fluid communication with the pluralityof apertures to create an air cushion between the support surface andthe green body to support the green body within the support area.

In another example aspect, an apparatus for producing a green body ofceramic-forming material comprises an extruding device including a diemember. The extruding device is configured to extrude a batch ofceramic-forming material through the die member along an extrusion axisto form a green body. A support device includes at least one adjustableair bearing including a support surface with a plurality of apertures. Aradial position of the support surface relative to the extrusion axis isconfigured to be adjusted. A fluid source is configured to be placed influid communication with the plurality of apertures to create an aircushion between the support surface and the green body.

In still another example, a method of producing a green body comprisesthe steps of extruding a batch of ceramic-forming material into a greenbody along an extrusion axis and radially constricting a plurality ofsupport segments of a plurality of adjustable air bearings such thateach of the support segments follows an outer surface portion of thegreen body. The method further includes the step of emitting fluid froma plurality of apertures of each of the support segments to create anair cushion between the plurality of support segments and the outersurface portion of the green body.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the presentinvention are better understood when the following detailed descriptionof the invention is read with reference to the accompanying drawings, inwhich:

FIG. 1 is a schematic view of an extrusion apparatus and air bearing inaccordance with aspects of the disclosure;

FIG. 2 is an enlarged partial sectional view of the die member of FIG.1;

FIG. 3 is a sectional view of a green body along line 3-3 of FIG. 1;

FIG. 4 illustrates an example air bearing along line 4-4 of FIG. 12;

FIG. 5 is a sectional view of an example air bearing along line 5-5 ofFIG. 12;

FIG. 6 is a sectional view of an example air bearing along line 6-6 ofFIG. 12;

FIG. 7 is a schematic view of a support surface of an air bearing alongline 7-7 of FIG. 5;

FIG. 8 is a sectional view of a support surface along line 8-8 of FIG.7;

FIG. 9 is another example sectional view of a support surface along line8-8 of FIG. 7;

FIG. 10 is a sectional view of a support surface along line 10-10 ofFIG. 7;

FIG. 11 is another example sectional view of a support surface alongline 10-10 of FIG. 7; and

FIG. 12 is a schematic illustration of an example a system of airbearings used to support and move a green body produced by the extrusionapparatus of FIG. 1.

DETAILED DESCRIPTION

The present invention will now be described more fully hereinafter withreference to the accompanying drawings in which example embodiments ofthe claimed invention are shown. Whenever possible, the same referencenumerals are used throughout the drawings to refer to the same or likeparts. However, the claimed invention may be embodied in many differentforms and should not be construed as limited to the embodiments setforth herein. These example embodiments are provided so that thisdisclosure will be both thorough and complete, and will fully convey thescope of the claimed invention to those skilled in the art.

As used in this specification, a “green body” is a structure or body ofceramic-forming material prior to firing. A “cellular structure,”“honeycomb structure,” or “body” includes any monolithic structurehaving inlet and outlet end faces, and having a matrix of walls defininga plurality of open-ended cells or passageways extending longitudinallyand mutually parallel through the body between the inlet and outlet endfaces of the body.

FIG. 1 illustrates a schematic view of an apparatus 10 for producing agreen body 12 of ceramic-forming material. The apparatus 10 includes anextruding device 14 that is configured to extrude a batch ofceramic-forming material through the die member 16 to form a green body12 of potentially unlimited length. Once the desired length is achieved,a cutter (not shown) can be used to sever the extruded green body 12 toprovide a segmented green body 12.

The illustrated apparatus 10 depicts a twin-screw extruder includingtwin screws 18 a, 18 b configured to be rotated by respective motors 19a, 19 b to mix and compress the batch of ceramic-forming material as ittravels along a path 20 toward the die member 16. The extruding device14 includes an extrusion axis 22 wherein the green body 12 can beextruded from the die member 16 along an extrusion direction 23substantially parallel to the extrusion axis 22.

FIG. 2 is an enlarged cross sectional view of an example die member 16that may be used in accordance with aspects of the disclosure. As shown,the die member 16 includes feed holes 24 configured to feed batchmaterial in direction 26, along the path 20, toward a plurality of diepins 28. The die pins 28 are spaced apart from one another to defineslots 30 designed to form the walls 32 of the honeycomb structure 34(best seen in FIG. 3) as the batch material is drawn into the extrudedgreen body 12. The die pins 28 shown in FIG. 2 can have a square shapeto define square-shaped channels 36 (best seen in FIG. 3) although otherdie pin 28 configurations (e.g., hexagonal, octagonal, etc.) can beselected depending on the desired channel configuration.

Returning to FIG. 1, the apparatus 10 includes a support device 50configured to support the extruded green body 12 as the green body 12 isextruded from the die member 16. The support device 50 can include atleast one air bearing 52 that may be used to produce an air cushion asdiscussed more fully below.

FIG. 4 illustrates an end view of the air bearing 52. As shown, the airbearing 52 can include a box frame 54 which defines at least oneinterior air chamber 56 (best seen in FIG. 5). If provided, the boxframe 54 can include at least one fluid inlet 58 allowing fluidcommunication between a fluid source 70 (best seen in FIG. 12) externalto the box frame 54 and the interior air chamber 56. In one example, theinterior air chamber 56 can be secured so that little or no ambientatmosphere can enter into the interior air chamber 56 during operationof the apparatus 10. The box frame 54 can be cube-shaped and constructedof metal, although other shapes and materials are contemplated.

Turning to FIG. 5, the air bearing 52 may include a support surface 60.In one example, the support surface 60 is constructed of a polymer,however other materials are contemplated. Material choice for thesupport surface 60 can be made on the basis of a low coefficient offriction between the support surface 60 and the extruded green body 12to help accommodate relative movement upon the occurrence of any contactbetween the support surface 60 and the green body 12. The supportsurface 60 includes a plurality of apertures 68 (best seen in FIG. 7)through which a pressurized fluid can pass. In one example, theapertures 68 are in fluid communication with the interior air chamber 56by way of a hollow support 62.

In one example, the support surface 60 can be rigidly connected to ahollow support 62. The hollow support 62 can be slidingly engaged withbushing 64 which is located in an aperture defined by the box frame 54.Aspects of the bushing 64 material selection can include a lowcoefficient of friction and self-lubricating features. In one example,the bushing 64 material is polytetrafluoroethylene (PTFE) such as Rulon®J of Saint-Gobain Performance Plastics Corporation. In another example,other bushing 64 types may be included such as ball bushings, splitbushings, press-fit bushings, etc.

As schematically shown in FIG. 12, a fluid source 70 may be configuredto be placed in fluid communication with the plurality of apertures 68to create an air cushion between the support surface 60 and the greenbody 12 to support the green body 12 within a support area 74 (see FIG.5). As shown, the fluid source 70 can be connected to the fluid inlet 58located on the box frame 54 of the air bearing 52. The fluid can beliquid, vapor, or gas. Additionally, when the fluid is a gas, such asair, the gas can be humidified to enhance a characteristic of theproduction quality. In one example, the fluid source 70 providespressurized air to the fluid inlet 58 which then pressurizes theinterior air chamber 56. The pressurized air then flows through thehollow support 62 and the bushing 64 to reach the support surface 60 andexit the air bearing 52 through the apertures 68 in the support surface60. The continuous supply of forced air is exerted through the apertures68 to floatingly support the green body 12. In the example, low pressureair is sufficient to create an air cushion between the support surface60 and the green body 12 so that the green body 12 may freely float inthe support area 74 without necessarily contacting the support surface60. However, various magnitudes of air pressure are contemplateddepending, for example, on factors such as the gap between the supportsurface 60 and the green body 12, and the density of the green body 12.

Although not required in all examples, the support surface 60 mayconfigured to circumscribe greater than 180° of the support area 74 forthe green body 12. As such, the support area 74 may be designed to helpmore securely center and hold the green body 12 in place during theextruding and/or severing procedure. The side of the support surface 60facing the support area 74 can be in the shape of a circular arc,although other non-circular shapes, such as ovals, are alsocontemplated. In one example, the support surface 60 is configured toprovide a support area 74 consisting of a portion of a cylinder that isabout 360°. In another example, the support surface 60 is configured toprovide a support area 74 consisting of a portion of a cylinder that isless than about 315°. In another example, the support surface 60circumscribes from about 215° to about 315° of the support area 74. Inyet another example, the support surface 60 circumscribes from about250° to about 280° of the support area 74. In still another example, thesupport surface 60 circumscribes about 265° of the support area 74.

One advantage of having a support area 74 circumscribing about 360° ofthe green body 12 includes developing better control of the movements ofthe green body 12 as it is supported by the air cushion. Anotheradvantage of having a support area 74 circumscribing about 360° of thegreen body 12 includes a greater possibility of eliminating rotation ofthe green body 12 as it exits the extruding device 14. Still moreadvantages of having a support area 74 circumscribing about 360° of thegreen body 12 include more even drying of the green body 12 and agreater tendency to maintain the green body 12 in a circularcross-section with decreased tendency of slump within the green body 12.In one example of a support area 74 circumscribing about 360° of thegreen body 12, pressurized air enters the support area 74 through theapertures 68, forms an air cushion to support and perhaps transport thegreen body 12, and then exits the support area 74 through the gapsbetween the support surfaces 60. In another example, evacuation portscan function in the same way as the gaps between the support surfaces 60to allow the pressurized air to exit the support area 74.

An advantage of having a support area 74 circumscribing less than 360°of the green body 12 includes a large space for pressurized air to exitthe support area 74. As an example, if the support area 74 circumscribesabout 315° of the green body 12, the pressurized air can leave thesupport area 74 through the space where no support surfaces 60 arelocated. Another advantage of having a support area 74 circumscribingless than 360° of the green body 12 includes greater ease in removingceramic-forming material from the support area 74 other than through thenormal operation of green body 12 motion along the extrusion axis 22. Asan example, circumscribing less than 360° can accommodate unexpectedprocess shut-down or inadvertent engagement of the green body 12 withthe support segments 82 or other green bodies 12. Inadvertent engagementmay break the green body 12 or render a green body 12 ineffective forfurther processing, requiring its removal from the support area 74. Inthese situations, the ceramic forming material can be removed from thesupport area 74 through the space where no support surfaces 60 arelocated.

Turning to FIG. 7, an example support surface 60 is shown in plan viewalong line 7-7 of FIG. 5. Extrusion axis 22 is overlaid the supportsurface 60 for clarification of the orientation of the support surface60. A plurality of apertures 68 are shown as an example of location andquantity, but many different locations and quantities of apertures 68can be used. Exemplary cross-sections of the apertures 68 are shownparallel and perpendicular to the extrusion axis 22 in FIGS. 8 and 9 andFIGS. 10 and 11, respectively. In further examples, the apertures 68 maybe spaced differently from one another and/or may have different sizesand/or shapes. As shown, the shape of the apertures 68 can besubstantially circular although the apertures 68 can include othershapes.

FIG. 8 is an example sectional view of a quantity of apertures 68 alongline 8-8 of FIG. 7 that is parallel to the extrusion axis 22. As shownin FIG. 8, the quantity of the apertures 68 can be oriented with a fluidemitting axis 78 a extending substantially perpendicular to theextrusion axis 22. The apertures 68 can have a fluid emitting axes 78 athat are directed radially toward the center of the green body 12. Thisfluid emitting axis 78 a orientation can be used for several objectives,the foremost being to counteract the effect of gravity upon the greenbody 12 so that the green body 12 freely floats above the supportsurface 60. Additional objectives include, but are not limited to,prevention of rotation of the green body 12 about the extrusion axis 22,and fostering a more even drying rate for the green body 12 to helpprevent skin or surface related flaw or “fissures” which may degrade theperformance or appearance of the finished product.

FIG. 9 is another example sectional view along line 8-8 of FIG. 7,demonstrating that the quantity of the apertures 68 can be oriented witha fluid emitting axis 78 b extending at an oblique angle with respect tothe extrusion axis 22. This fluid emitting axis 78 b orientation can beused to urge the green body 12 in the extrusion direction 23 parallel tothe extrusion axis 22. As such, the fluid emitting from the apertures 68can engage the green body 12 with one force component perpendicular tothe green body 12 to help counterbalance the green body 12 with acushion of air. At the same time, a force may be provided in theextrusion direction 23 to encourage movement (e.g., transport) of thegreen body 12 in the extrusion direction 23, thereby facilitatingextrusion of the green body 12 from the die member 16.

FIG. 10 is an example sectional view of a quantity of apertures 68 alongline 10-10 of FIG. 7 that is perpendicular to the extrusion axis 22. Asshown in FIG. 10, a quantity of the apertures 68 can be oriented with afluid emitting axis 78 c extending with a directional component that istransverse with respect to an extrusion direction 23 along an extrusionaxis 22. This fluid emitting axis 78 c orientation can be used bias thegreen body 12 to apply a rotational moment force to the green body 12about the extrusion axis 22. In one example, a quantity of the fluidstreams each apply a force component to an outer surface 46 of the greenbody 12 that is transverse with respect to the extrusion axis 22. Atransverse force, such as a force tangent to the surface of the greenbody 12, may apply a moment arm about the extrusion axis 22. This forcecomponent is created by the pressurized fluid emitted from a quantity ofthe apertures 68 at a transverse angle with respect to the extrusionaxis 22 can counteract a tendency of the green body 12 to rotate in theopposite direction as the green body 12 is extruded from the die member16.

Turning to FIG. 11, a quantity of the apertures 68 can be oriented witha fluid emitting axis 78 d extending with a directional component thatextends perpendicular to the extrusion axis 22 of the extruding device14. The force of the apertures 68 in this orientation counteracts theeffect of gravity upon the green body 12 so that the green body 12freely floats by way of an air cushion above the support surface 60. Itis to be understood that the orientation of the fluid emitting axis ofthe apertures 68 can include any combination of the describedorientations to freely float, urge motion, or resist motion of the greenbody 12 on various support surfaces 60 or within the same supportsurface 60 as the green body 12 proceeds through the manufacturingprocess. As such, the delicate honeycomb arrangement of the green body12 may be preserved as it is extruded from the die member 16.

Returning to FIG. 7, the apertures 68 at an end of the support surfaces60 can be of one type of emitting axis while the apertures 68 in otherportions of the support surface 60, e.g., the central portion of thesupport surface 60, are of a different emitting axis. This arrangementallows more functional control of the green body 12 as it enters andexits each individual air bearing 52. In one example, fluid emittingaxis of the apertures 68 at one end of a support surface 60 can betangential to the green body 12 while the fluid emitting axis of theapertures 68 at the central portion of the support surface 60 can beperpendicular to the green body 12.

Returning to FIG. 5, in one example of an air bearing 52, the airbearing 52 includes a support surface 60 that is radially adjustable toaccommodate geometrically similar green bodies 12 with different sizes.Relative motion between the hollow support 62 and the bushing 64 allowsthe support surface 60 to move, such as through rotation, translation,etc. through a continuum of positions. Each position is configured tofollow a portion of an outer surface 46 of the green body 12. Each ofthe positions can create a support area 74 that is concentric with everyother support area 74 created by other support surface 60 positions. Inone example, the air bearing 52 has a support surface 60 that can beadjusted to a position to freely float and transport a green body 12having a diameter between +0.4 inches and −0.4 inches from a nominalgreen body 12 diameter. It is to be appreciated that other ranges ofdiameters are also contemplated.

In another example of an air bearing 52, the air bearing 52 isadjustable to accommodate a green body 12 having a different geometricalshape. As an example, in one position, the support surface 60 can createa support area 74 of circular cross-section. After an adjustment, thesupport surface 60 can create a support area 74 of an oval-shapedcross-section.

Returning to FIG. 1, in another embodiment of the apparatus 10, theapparatus 10 comprises an extruding device 14 including a die member 16.The extruding device 14 is configured to extrude a batch ofceramic-forming material through the die member 16 to form a green body12. A support device 50 includes at least one air bearing 52 with aplurality of apertures 68. At least a quantity of apertures 68 areoriented with a fluid emitting axis 78 b extending at an oblique anglewith respect to the extrusion axis 22. This fluid emitting axis 78 borientation can be used to urge the green body 12 in a directionparallel to the extrusion axis 22. In one example, the fluid emittingaxis 78 b extending at an oblique angle with respect to the extrusionaxis 22 contributes a force component to the green body 12 in theextrusion direction 23 parallel to the extrusion axis 22 and away fromthe die member 16. This force component is created by the pressurizedfluid emitted from a quantity of the apertures 68 at an oblique anglewith respect to an extrusion axis 22 so as to urge the green body 12 toanother air bearing 52, further processing equipment, or the like. Theapparatus 10 further includes a fluid source 70 configured to be placedin fluid communication with the plurality of apertures 68 to create anair cushion between the support surface 60 and the green body 12.

In yet another embodiment of the apparatus 10, the apparatus 10comprises an extruding device 14 including a die member 16. Theextruding device 14 is configured to extrude a batch of ceramic-formingmaterial through the die member 16 to form a green body 12. A supportdevice 50 includes at least one radially adjustable air bearing 52. Theair bearing 52 includes a support surface 60 with a plurality ofapertures 68, wherein a position of the support surface 60 relative tothe extrusion axis 22 is configured to be adjusted. The support surface60 can be configured to circumscribe greater than 180° of a support area74 for the green body 12.

As an illustrative example, the apparatus 10 includes an air bearing 52that includes a support surface 60 that is adjustable by lineartranslation through a continuum of positions. Each of the positions cancreate a support area 74 that is concentric with every other supportarea 74 created by other support surface 60 positions. In one example,the air bearing 52 has a support surface 60 that can be adjusted to aposition to accommodate geometrically similar green bodies 12 withdifferent sizes. The air bearing 52 can freely float and transport agreen body 12 having a diameter between +0.4 inches and −0.4 inches froma nominal diameter of the green body 12. It is to be appreciated thatother ranges of diameters are also contemplated. Additionally, theapparatus 10 includes a fluid source 70 is configured to be placed influid communication with the plurality of apertures 68 to create an aircushion between the support surface 60 and the green body 12.

Returning to FIG. 5, in one example, the apparatus 10 includes at leastone adjustable air bearing 52. The at least one adjustable air bearing52 includes a plurality of air bearings 52 that each include acorresponding support segment 82. Each support segment 82 can include aquantity of the plurality of apertures 68. The plurality of supportsegments 82 is configured to cooperate to define the support surface 60.The side of the support segment 82 facing the support area 74 can be inthe shape of a circular arc. When each support segment 82 has the formof a circular arc profile, the plurality of support segments 82 can,together, form a larger arcuate segment of a circle or other arcuate(e.g., oval) shape. It is to be appreciated that other shapes for thesupport segments 82 are also contemplated, for example segments of ovalsso that when used together, form a support surface 60 with anoval-shaped profile.

The support segments 82 can be configured to be radially adjustedbetween an extended and retracted position. Relative motion between thehollow support 62 and the bushing 64 allows the support segment 82 tomove, such as through rotation, translation, etc. through a continuum ofpositions. The translation of each support segment 82 follows a radialpath from the extended and retracted positions. Each of the positionscan create a support area 74 that is concentric with every other supportarea 74 created by other support segment 82 positions. In one example,the air bearing 52 has support segments 82 that can be adjusted to aposition to freely float and transport a green body 12 having a diameterbetween +0.4 inches and −0.4 inches from a nominal green body 12diameter. It is to be appreciated that other ranges of diameters arealso contemplated.

Referring to FIG. 6, the support device 50 can include a diameteradjustment lever 84. The diameter adjustment lever 84 can be arcuate orcircular in shape, although other shapes are contemplated. At least oneslot 86 is provided in the diameter adjustment lever 84 such that oneend of the slot 86 is located at a longer distance from the center ofthe circular diameter adjustment lever 84. The diameter adjustment lever84 can be slidably attached to at least one shaft 88 at the slot 86 witha connection such as a pin, roller bearings, or other connectionmethods. In one example, the at least one shaft 88 can be rigidlyconnected to a support segment 82.

Because the slot 86 end points are at different radial distances fromthe center of the diameter adjustment lever 84, circumferential movementof the diameter adjustment lever 84 simultaneously extends or retractsthe shafts 88 with respect to the extrusion axis 22. This radialmovement of the shaft 88 thus moves the support segments 82 through acontinuum of positions resulting in an air bearing support surface 60with an adjustable diameter, each of the positions being concentric withany of the other positions. Radial movement of the shafts 88 and supportsegments 82 is guided by the sliding engagement of the hollow support 62with bushing 64.

Referring to FIG. 12, several air bearings 52 a, 52 b, 52 c, similar oridentical to the air bearing 52 discussed above, can be placed in seriesat the end of the extruding device 14. Green bodies 12 can then leavethe extruding device 14 and be floatingly supported and even transportedby a series of air bearings 52 a, 52 b, 52 c. In one example, each airbearing 52 can be controlled manually. In another example, each airbearing 52 can be interconnected by a master control system. Aperipheral measuring device 102 can be located at the end of the airbearing 52 that serves as an entrance for the green body 12. Peripheralmeasuring devices 102 a, 102 b, 102 c can be associated with each of theair bearings 52 a, 52 b, 52 c to detect certain productioncharacteristics (e.g., the shape, size, and irregularities of the outersurface 46) of the green body 12 as it enters the respective airbearings 52 a, 52 b, 52 c. Each peripheral measuring device 102 a, 102b, 102 c can then communicate with the logic unit 104 via electricalconnections 106 a, 106 b, 106 c. The logic unit 104 can also bedescribed as a controller.

The logic unit 104 can evaluate the production characteristics of thegreen body 12 located within each air bearing 52. The logic unit 104then communicates with actuators 108 a, 108 b, 108 c associated witheach diameter adjustment lever 84 a, 84 b, 84 c of each air bearing 52a, 52 b, 52 c. The logic unit 104 can communicate with each diameteradjustment lever 84 a, 84 b, 84 c via electrical connections 110 a, 110b, 110 c to adjust the support surface 60 according to the productioncharacteristics of the green body 12. The actuators 108 a, 108 b, 108 ccan then be each selectively activated to provide a predetermined moveof the respective adjustment lever 84 a, 84 b, 84 c to create a supportsurface 60 that accurately follows the outer surface 46 of the greenbody 12. The logic unit 104 can automatically control adjustments of theplurality of support segments 82 in response to a change in surfacecharacteristic of the green body 12 as the green body 12 travels in theextrusion direction 23 based on feedback from the peripheral measuringdevices 102 a, 102 b, 102 c. As such, the series of air bearings 52 canaccommodate for changes in the shape of the green body 12, e.g., due toshrinkage, etc.

The logic unit 104 can also communicate with a manifold 112 viaelectrical connection 114. The manifold 112 can comprise a plurality ofsolenoid valves (not shown), for example, one solenoid valve for eachfluid inlet 58 located on the air bearings 52 a, 52 b, 52 c. Thesolenoid valves can be configured to control the flow of pressurizedfluid from the manifold 112 to each fluid inlet 58. In one example, thelogic unit 104 can control simultaneous activation of the solenoidvalves in substantially the same manner. Alternatively, the logic unit104 can also control each solenoid valve on an individual basisaccording to the production characteristics of the green body 12 in eachair bearing 52 a, 52 b, 52 c. The logic unit 104 can also independentlycontrol each air bearing 52 a, 52 b, 52 c as a unit according to theproduction characteristics of the green body 12 within the air bearing52 a, 52 b, 52 c. The manifold 112 and each fluid inlet 58 are in fluidcommunication via tubing, piping, or any other appropriate means. Thelogic unit 104 can include a feedback loop.

Methods of producing a green body 12 will now be described. The methodincludes the step of extruding a batch of ceramic-forming material intoa green body 12. Various ceramic-forming batch materials and/orcompositions may be used in various examples. The method furtherincludes the step of supporting the green body 12 with an air cushionproduced by an air bearing 52 having a support surface 60 circumscribinggreater than 180° of the green body 12. Various angles of supportsurface 60 circumscribing the green body 12 can be used. In one example,the support surface 60 is configured to provide a portion of a cylinderthat is less than about 315°. In another example, the support surface 60circumscribes from about 215° to about 315° of the green body 12. In yetanother example, the support surface 60 circumscribes from about 250° toabout 280° of the green body 12. In still another example, the supportsurface 60 circumscribes about 265° of the green body 12.

In another method of producing a green body 12, the method includes thestep of extruding a batch of ceramic-forming material into a green body12 along an extrusion axis 22. The method further includes the step ofsupporting the green body 12 with an air cushion produced by a pluralityof fluid streams. At least a quantity of the fluid streams each apply atransverse force component to an outer surface 46 of the green body 12.In one example, the transverse force component of the emitted fluid isin the direction parallel to the extrusion axis 22 and away from theextruding device 14. The method can also comprise the step of biasingthe green body 12 to move in an extrusion direction 23 along theextrusion axis 22 with a plurality of the oblique force components.These force components are created by the pressurized fluid emitted froma quantity of the apertures 68 at an oblique angle with respect to theextrusion axis 22 so as to urge the green body 12 in a directionparallel to the extrusion axis 22.

The method can further comprise the step of biasing the green body 12 toapply a rotational moment force to the green body 12 about the extrusionaxis 22 with a plurality of the transverse force components. Forinstance, a quantity of the fluid streams can each apply a forcecomponent to an outer surface 46 of the green body 12 that is transversewith respect to the extrusion axis 22. This transverse force componentof the emitted fluid can be in a direction perpendicular to theextrusion axis 22 at a distance away from the extrusion axis 22, thusapplying a moment arm about the extrusion axis 22. This force componentis created by the pressurized fluid emitted from a quantity of theapertures 68 at a transverse angle with respect to the extrusion axis 22so as to provide a moment force to the green body 12 that can counteracta tendency of the green body 12 to rotate as it is extruded from the diemember 16.

In another method of producing a green body 12, the method comprises thestep of extruding a batch of ceramic-forming material into a green body12 along an extrusion axis 22. The method further comprises the step ofradially constricting a plurality of support surfaces 60 of a pluralityof adjustable air bearings 52 to follow an outer surface 46 portion ofthe green body 12. The method further comprises the step of emittingfluid from a plurality of apertures 68 of each of the plurality ofsupport surfaces 60 to create an air cushion between the plurality ofsupport segments 82 and the outer surface 46 portion of the green body12.

In one example of the method, the step of radially constricting theplurality of support segments 82 is conducted after an end of the greenbody 12 enters a support area 74 defined by the support surfaces 60. Thediameter adjustment lever 84 can be operated to move the supportsurfaces 60 through a continuum of positions resulting in an air bearing52 support surface 60 with an adjustable diameter, each of the positionsconfigured to follow an outer surface 46 portion of the green body 12.Constricting the plurality of support segments 82 after an end of thegreen body 12 enters the support area 74 allows the support area 74 tobe accurately positioned to follow an actual diameter of the outersurface 46 portion of the green body 12, not an anticipated diameter.Thus, the constriction can then account for miscalculations ofanticipated green body 12 diameters, unexpected water content in thegreen body 12 resulting in a larger diameter of the green body 12, etc.The constriction can be initiated manually or initiated automatically bya control system associated with the air bearing 52. In one example, thesupport surface 60 can be at its most dilated position until the greenbody 12 enters the support area 74. At that time, the support surface 60can be constricted to meet the production characteristics of theparticular green body 12 that is located within the support area 74. Assuch, the initial retraction of the support segments 82 can avoidinadvertent engagement of the end of the green body 12 with the supportsegments 82 that might otherwise occur if the support surfaces 60 areextended before the green body 12 enters the support area 74. As such,damage to the end of the green body 12 and interruption of themicrostructure of the honeycomb walls 32 of the green body 12 can beavoided.

The method can also comprise the step of automatically adjusting theplurality of support segments 82 in response to a change in surfacecharacteristic of the green body 12. In one example, the surfacecharacteristic can be the outer diameter of the green body 12. As thegreen body 12 gradually loses moisture content, the outer diameter ofthe green body 12 can change. In order to accurately follow the outersurface 46 portion of the green body 12, successive air bearings 52 mayhave to constrict or expand the support area 74.

The described extrusion apparatus 10 and air bearing 52 provide severalbenefits. One adjustable air bearing 52 may be able to support andtransfer various diameters of green bodies 12, thus able to replaceseveral existing models of air bearings 52 that are not adjustable andare configured to support and transfer only a single diameter green body12. Additionally, a single adjustable air bearing 52 can also supportand transfer green bodies 12 with different cross-sectional geometries.Furthermore, the adjustable air bearing 52 can more accurately support agreen body 12 through angles greater than 180°, thereby enhancingsupport of the green body 12 and helping further support the green body12 during a severing operation. Still further, the more accurate supportof the green body 12 through angles greater than 180° can also fostereven drying of the green body 12 and reduce surface defects such asfissures that can degrade performance of the finished product. The greenbody 12 floats on an air cushion provided by pressurized air emittedfrom apertures 68 in the support surfaces 60. The fluid emitting axis ofeach aperture 68 can be modified to induce translational motion of thegreen body 12, rotational bias to the green body 12, or elimination orreduction of undesirable motion of the green body 12.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the present inventionwithout departing from the spirit and scope of the invention. Thus, itis intended that the present invention cover the modifications andvariations of this invention provided they come within the scope of theappended claims and their equivalents.

What is claimed is:
 1. An apparatus for transporting a cellular structure, the apparatus comprising: a support device comprising a plurality of support segments of radially adjustable air bearings each comprising a support surface with a plurality of apertures, wherein the support surfaces circumscribe greater than 180° of a support area for the cellular structure, and wherein the radial adjustment is provided by a radially sliding engagement; and a fluid source configured to be placed in fluid communication with the plurality of apertures to create an air cushion between the support surface and the cellular structure so that the cellular structure may freely float within the support area.
 2. The apparatus of claim 1, wherein the support surfaces circumscribe from greater than 180° to about 360° of the support area.
 3. The apparatus of claim 1, wherein the support surfaces circumscribe from about 215° to about 315° of the support area.
 4. The apparatus of claim 1, wherein the support surfaces circumscribe from about 250° to about 280° of the support area.
 5. The apparatus of claim 1, wherein the support surfaces circumscribe about 265° of the support area.
 6. The apparatus of claim 1, wherein at least a quantity of the apertures are oriented with a fluid emitting axis extending substantially perpendicular to an extrusion axis of the extruding device.
 7. The apparatus of claim 1, wherein at least a quantity of the apertures are oriented with a fluid emitting axis extending at an oblique angle with respect to an extrusion axis of the extruding device.
 8. The apparatus of claim 1, wherein at least a quantity of the apertures are oriented with a fluid emitting axis extending with a directional component that extends at an oblique angle with respect to an extrusion direction along an extrusion axis of the extruding device.
 9. The apparatus of claim 1, wherein at least a quantity of the apertures are oriented with a fluid emitting axis extending with a directional component that extends parallel to an extrusion direction along an extrusion axis of the extruding device.
 10. The apparatus of claim 1, wherein the radial adjustment accommodates green bodies of different cross-sections, diameters or profiles.
 11. The apparatus of claim 1, wherein the radial adjustment accommodates green bodies having different geometrical shapes. 